Okay well i am having some problems and dont have much time to fix them. There are two different things that seemed to happen this winter hopefully you guys can give me some pointers.

TRUCK SPECS
1991.5 Dodge W250 Intercooled
298,000 miles

PROBLEM 1
The truck was running fine all last year. This winter it got very cold so i put some additive to make sure it didnt freeze and filled up the tank. Everything was great no problems at all until i started getting low on fuel. At that point it all started.

I will be driving and randomly the truck will just fall on its face. Almost like fuel cut on modern cars. Here is what confuses me. When this happens my foot is steady on the gas. When it happens if i keep my foot steady on the gas it just keeps slowing down like the engine shut off. But if i let up on the gas then press it back down everything is fine.

THINGS I HAVE DONE
1) I changed the lift pump about 1000 miles ago.
2) Filled the tank up again from a different gas station
3) I changed the fuel filter today to see if that was the problem "didnt work"

PROBLEM 2
Since it has been a bad winter the truck has been in 4wd since November. Everything has been okay no problems. Well the roads cleared and i took it out of 4wd and now i get a terrible grinding - rattling - sound coming from the transfer case in 2wd. If i put it back in 4wd the sound goes away and everything is fine.

THINGS I HAVE DONE
1) Tried various steps of unlocking the hubs and changing from 4wd to 2wd.

This is my work truck and the season is getting ready to start. So im trying to figure out if its going to be worth fixing the problems noted or should i be looking for a new work truck?

Thanks for your time
Chris

 

I would hook up a gauge and test fuel pressure. It sounds like it may be a supply problem, or an aeration problem. I had a 92 truck do this last week, the problem turned out to be the lift pump that I installed six months ago.

 

TC noise may be a shifting fork that needs adjusted with the linkage. Just a good guess.

 

Check the oil level in the TC. Its common for the lever on most to hum at speed. put a glove over the **** and see if that quiets it or I believe there is a sticky on how to fix the humm coming from the TC lever.

Check your wire on the shut off soleniod. But it sounds like you have an air leak or supply issue.

 

Problem #1

Check or better yet replace the two connections to the fuel shut off valve. I saw the same problem and found that the factory connections can loosen up and cause intermitent symptoms exactly as you describe. Some have replaced the slide on terminals with ring terminals thus eliminating the problem once and for all.

Bob

 

Thanks Guys! I will replace and change to ring terminals on the fuel shutoff tomorrow and see if that fixes it.

The Transfer Case i guess might be low on fluid i will also check that. But i dont understand why it would not grind in both 4wd and 2wd if that was the case. But it definitely is not the HUM sound that was posted above. The sound it is making in 2wd sounds like gears or metal slapping against metal. Probably one of the worst sounds i have heard come out of a vehicle..lol..

SIDE NOTE: After i changed the Fuel Filter today when i took it out i dont have any turn signals anymore. Not sure if all this can be tied together wire related or not but thought i would add that.

Thank You Again!
Chris

 

You probably ought to drop your fuel tank and examine the fuel pick-up. It's common for them to get gunked up with crud, and it's also not unheard of for one of the screws in the assembly to worry a hole in the pickup hose.

I suspect a restricted pickup because your trouble started after running low on fuel.

 

After my post yesterday about dropping the tank I drove the truck to town with no issue on the way home it started soing exactly as you say falling flat on its face again and now its more frequent.

 

Thanks for the info everybody.

When i cut my old fuel filter open yesterday it was perfectly clean. Do you still believe i should drop the tank wanna if the fuel solenoid wires are good?

Lets us know if the Fuel solenoid works. Im going to try and get out there today but its 22 degrees and 15mph winds. Hopefully it clears.

 

I'd install a pressure gauge in the cab before I went to the trouble of dropping the tank. Then you will know if it's a supply problem or something much much worse.

 

you can also blow compressed air through the fuel supply line & blow the sock off in the tank until you have time to drop the tank I have done to many gas engines i believe it would work the same for your diesel

 

Okay i will get a gauge tomorrow. Do i just connect it to the bleed valve where i believe you guys say to put a gauge in the engine bay? Or is there a better spot to run it into the cabin?

Thanks
Chris

 

Okay what can be the adverse effects here? Just clogging my fuel filter more if the sock is blown off? Or if i do this and run the engine can i cause more harm then good in the long run?

Thanks
Chris

 

if your tank is full of garbage the fuel filter should stop it this would be a temporary fix untill you could pull take & replace sock I have run without sock with out problems but that may not be the correct way but it will also go thru your lift pump I have a Aux filter before piston lift pump so i can run wvo

 

Okay i fixed all the wiring today. Fixed all the loose connections with ring terminals. I found the main ground from the battery to the battery support was good but then there was a second ground from the battery to the battery support that was broke. There was also another ground running into a loom on the driver side fender that was broke.

I then found that my Hard Line that runs from the top of the Fuel Pump to the cylinder head was broke. I fixed the hard line and was putting the banjo bolt back on when i broke the banjo bolt.

I am now drilling and tapping the M8 1.0 banjo bolt hole to a 1/8 NPT fitting. I am then installing quick disconnect fittings to replace the factory hard line.

Could any of this been my problem? Since i have the top of the pump apart i figure i might as well do some pump mods. Any good starting pump for the star wheel and stuff?

Thanks
Chris